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Amada UB25 User Manual

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990-665 REV J
LINEAR DC RESISTANCE WELDING CONTROL
UB25
OPERATION MANUAL

Table of Contents

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Amada UB25 Specifications

General IconGeneral
ModelUB25
CategoryWelding System
Max. Welding Thickness2.5 mm
Max. Welding Width250 mm
Power Supply220V, 50/60Hz

Summary

CHAPTER 1 DESCRIPTION

Section I. Introduction

Provides an overview of the UB25 Linear DC Welding Control and its features.

Section II. Description

Details the UB25 front panel, controls, indicators, and rear panel connections.

Section III. Overview

Explains the LCD screens, menu screens, data screens, and operational states.

Section IV. Controls and Indicators

Describes the front panel controls and indicators like LCD, keypad, and selector keys.

Section V. Emergency Stop Switch and 24V Jumpers

Details the emergency stop switch functionality and 24V jumpers.

Section VI. Related Publications

Lists related publications for further information.

CHAPTER 2 GETTING STARTED

Section I: Planning for Installation

Covers space requirements, utilities, and installation considerations.

Section II: Unpacking

Provides instructions for unpacking the equipment and verifying contents.

Section III. Electrical and Data Connections

Explains how to make electrical and data connections on the rear panel.

Section IV. Setup

Details manual and air-actuated weld head connections and setup.

CHAPTER 3 Using UB25 Welding and Monitoring Functions

Section I: Introduction

Introduces welding and monitoring functions for accurate and consistent welds.

Section II. Weld Schedules

Explains weld schedules, definition, sequence timing, and applications.

Section III. Programmable Feedback Modes

Describes current, voltage, and power feedback modes for weld schedules.

Section IV. Weld Monitor

Covers weld monitor features like APC, energy limits, and pre-weld checks.

CHAPTER 4 OPERATING INSTRUCTIONS

Section I: Introduction

Outlines how to operate the Power Supply, including setup and programming.

Section II: Initial Setup

Guides through pre-operational checks and initial setup instructions.

Section III. Programming Weld Schedules

Details how to program single-pulse, upslope/downslope, and dual-pulse schedules.

Section IV. Programming the Weld Monitor

Explains how to program the weld monitor settings and limits.

Section V. Programming For Active Part Conditioning

Provides instructions for programming Active Part Conditioning features.

Section VI. Operation

Covers general operator safety, manual, and automated welding operations.

CHAPTER 5 SETUP SOFTWARE

Section I: Introduction

Introduces the setup software and its flexibility in configuring the system.

Section II. How to Use Menu Screens

Explains how to navigate and use the main menu and setup menus.

Section III. Operator Preferences

Covers settings for display contrast, buzzer loudness, and cycle buzzers.

Section IV. System Settings

Details system settings for waveform check, lockout, debounce, and switches.

Section V. PID Test Weld Setup

Explains PID test weld setup, including do test weld options and ignore first/last.

Section VI. Relay Settings

Describes how to program relay activation and timing for various conditions.

Section VII. Special Functions

Covers functions like copying schedules and resetting defaults.

Section VIII. Communication and Data

Details communication settings, ID number, and baud rate for data transfer.

CHAPTER 6 USER MAINTENANCE

Section I: Precautions

Outlines general operator safety precautions.

Section II: Operator Maintenance

Specifies operator maintenance requirements, primarily calibration.

Section III: Troubleshooting

Provides guidance on troubleshooting common problems and alarm messages.

CHAPTER 7 CALIBRATION

Section I. Introduction

Introduces the calibration process and required equipment.

Section II. Calibration Equipment Setup

Details the setup of calibration equipment.

Section III. Calibration Procedure

Provides step-by-step instructions for performing calibration.

APPENDIX A TECHNICAL SPECIFICATIONS

General

Lists general technical specifications for the UB25 power supply.

Mechanical Characteristics

Details the physical dimensions and weight of the unit.

Environmental Characteristics

Specifies operating ambient air temperature and humidity ranges.

Interface Signals

Describes input/output signals, connectors, and communication interfaces.

Firmware

Notes that firmware is subject to change without notice.

APPENDIX B ELECTRICAL AND DATA CONNECTORS

Introduction

Introduces the electrical and data connectors on the rear panel.

Voltage Sense Input

Details the voltage sense input connector specifications and pinout.

RS-485 IN and RS-485 OUT

Explains the RS-485 connectors, pinout, and specifications.

RS-232

Details the RS-232 connector specifications and pinout.

I/O Signal Interface A

Describes the I/O Signal Interface A connector and its specifications.

I/O Signal Interface B

Describes the I/O Signal Interface B connector and its specifications.

Air Valve Driver 24V

Details the air valve driver connector specifications.

Firing Switch

Provides specifications for the firing switch connector.

Foot Switch

Details the foot switch connector specifications.

AC Input Power Connection

Explains the AC input power connection and specifications.

Weld Terminals

Describes the weld terminals and their specifications.

APPENDIX C THE BASICS OF RESISTANCE WELDING

Resistance Welding Parameters

Explains the fundamental parameters of resistance welding.

Welding Parameter Interaction

Illustrates how heat, time, and force interact in welding.

Electrode Selection

Guides on selecting appropriate electrode materials for different applications.

Electrode Maintenance

Provides information on electrode maintenance and cleaning.

Weld Schedule Development

Outlines the procedure for developing effective weld schedules.

Weld Strength Testing

Describes methods for testing weld strength.

Weld Strength Profiles

Explains how to create weld strength profiles for parameter optimization.

APPENDIX D Defining the Optimum Process

Introduction

Introduces defining optimum resistance welding processes and key considerations.

Resistance Welding - A Material World

Discusses material properties and their impact on welding.

Consider the Material Properties

Details material properties like resistivity, melting point, and hardness.

Basic Principles

Explains fundamental principles of resistance welding, including resistance types.

Weld Profiles

Defines basic welding profiles and energy application over time.

Approach to Weld Development

Outlines a systematic approach to developing welding processes.

Initial Welding Trials -- The “Look See” Tests

Describes initial experiments to establish weld parameters.

Common Problems

Identifies common process problems related to materials and positioning.

What are Screening DOE’S?

Explains Screening Design of Experiments for parameter impact analysis.

What are Factorial DOE’S?

Defines Factorial Design of Experiments for optimizing settings.

Criteria for Success

Sets criteria for successful experimental design and parameter selection.

Conclusion

Summarizes the importance of a methodical approach to welding process definition.

APPENDIX E LCD DISPLAY MESSAGES

Introduction

Introduces the types of messages displayed on the LCD screen.

Relay Activation

Explains how alarm and out-of-limits messages activate relays.

Clearing Alarm Conditions to Resume Operation

Provides steps to clear alarm conditions and resume operation.

List of Messages

Lists and explains various LCD display messages.

APPENDIX F RELAY TIMING DIAGRAMS

Introduction

Introduces relay setup and timing diagrams for different states.

WELD

Shows the timing sequence for the WELD relay state.

END OF WELD

Displays the timing sequence for the END OF WELD relay state.

ALARM

Illustrates the timing sequence for the ALARM relay state.

OUT OF LIMITS

Details the timing sequence for OUT OF LIMITS relay conditions.

APPENDIX G REPETITION RATES

Introduction

Defines repetition rate and its dependency on recharging time.

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